DR-5 Workstation Scooter Controller Testing System

The 5-station electric scooter controller testing system is an intelligent multi-station parallel detection platform specifically designed for electric scooter controllers (ECUs). By integrating five independent test stations, it simultaneously conducts full-dimensional tests on the electrical performance, communication protocols, environmental adaptability, and EMC immunity of the controllers. This system is widely used in controller mass production, incoming material inspection in vehicle manufacturers, R&D laboratories, and certification institutions, ensuring that products comply with international standards such as ISO 26262, EN 15194, and UL 2272, providing core support for high-efficiency, zero-defect intelligent manufacturing.

Application scope

Used for electric scooter control system testing. 

Core functional modules 

Multi-station parallel testing

Independent control stations: 5 stations operate independently, supporting synchronous testing of different model controllers without interference, increasing efficiency by 500%.

Quick changeover design: Modular fixtures (compatible with brushless and brushed controllers), changeover time ≤ 3 minutes, suitable for wheel diameters of 6 to 12 inches.

Full parameter automated testing

Electrical performance testing:

1. Voltage range: 24V to 60V (expandable to 120V), current 0 to 100A (accuracy ±0.1% FS), verifying overvoltage/undervoltage protection and locked rotor current response.

2. PWM speed control accuracy: Duty cycle 0 to 100%, linear error < ±0.5%.

Communication protocol verification: Supports CAN, UART, and I²C protocol parsing, automatically verifying speed commands, fault codes, and temperature feedback data frames.

Environmental and reliability testing

Temperature and humidity cycling: Each station has independent temperature control (-40°C to +120°C, humidity 10% to 95% RH), testing high-temperature derating and low-temperature startup performance.

Vibration testing: Random vibration (5 to 500Hz, acceleration 10g), verifying the strength of controller solder joints and component vibration resistance.

Intelligent management

AI fault prediction: Machine learning algorithms analyze historical data to predict potential defects (such as MOSFET aging and capacitor value degradation).

Data traceability: Each station independently generates PDF reports (including waveform diagrams and protocol logs), supporting MES system integration and batch traceability. 

Core technologies and configurations

Product advantages 

Technical Highlights

High-precision power matrix: 5-channel programmable DC power supply + electronic load, dynamic response ≤ 1ms, supports energy feedback (energy-saving rate ≥ 30%).

Modular expansion:

1. Optional EMC test module (radiation/conduction immunity, compliant with ISO 11452-2).

2. Upgradable to 8/10 stations to meet larger-scale production needs.

Safety protection:

1. Each station has independent overcurrent/short circuit/over-temperature protection, compliant with CE/UL electrical safety standards.

2. Fully enclosed protective cover + emergency stop button, certified by ISO 13849 mechanical safety.

System advantages

High efficiency and accuracy:

1. Single-station test cycle ≤ 2 minutes, 5-station parallel daily inspection volume increases by 5 times.

2. Data consistency error < ±0.3%, supports automatic sorting of defective products (optional mechanical arm).

Flexible adaptation:

1. Compatible with scooter, balance bike, and electric bicycle controllers, supports customer-defined test scripts.

2. Independent maintenance of each station, single-station failure does not affect overall operation.

Cost optimization:

1. Reduces manual intervention by 80%, lowers quality inspection costs by 60%.

2. Reduces after-sales repair costs and brand risks through early defect interception.

Standard compliance: Built-in ISO 26262 functional safety test process, one-click generation of ASPICE/ISO 21434 compliance reports. 

Application scenarios and industry value

Batch production quality inspection: Quick screening of all items before the controller leaves the factory (5 workstations test simultaneously, daily output ≥ 2000 units).

Incoming inspection for vehicle manufacturers: Quick random inspection of the matching between the controller and the motor, BMS to avoid functional abnormalities after installation.

Research and development verification: Parallel comparison tests of multiple controllers (such as performance differences of different cooling solutions, firmware versions).

Certification testing: Compulsory testing of EMC and environmental adaptability in standards such as CE, FCC, GB. 

After-sales Service

Warranty Policy: Most manufacturers offer a one-year full machine warranty, supporting remote fault diagnosis and operation training.

Customization Service: Customization based on requirements, including custom fixtures and software functions according to testing standards (such as JIS/CNS) to meet special needs.

After-sales Service: One-year full machine warranty, providing operation training and remote technical support.

Data Service: Optional cloud data platform for generating CNAS-compliant test reports remotely.

Technical Support: Free remote debugging, operation training, and annual equipment calibration services.

Spares Supply: Quick replacement service for consumable parts (fixtures, hydraulic seals). 

Ordering Process

Requirement Communication: Provide test standards and relevant parameters.

Plan Confirmation: The supplier provides 3D drawings and parameter lists.

Production and Delivery: 15-20 days for standard models, 30-45 days for non-standard custom models.

Acceptance and Training: Engineers will install and debug on-site and provide training.